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There are three main types of wires when we classify them based on the material used for manufacturing. They are Steel, Aluminum, and Copper.As each material has its distinct characteristics, advantages, and disadvantages, they find their usage in various industries.
Cost-Effective: Steel Wires are often used as they are more cost-effective than other materials like Tungsten.
Strength: Steel Wires are more robust when compared to aluminum and other materials. Steel wires of grade 301, 304 possess a tensile strength of more than 1000 MPa in wire forms.
Poor conductor of Electricity: Steel Wire is a poor conductor of electricity. As a result, the person needs to use a lot of steel wire to transmit electricity over a long distance. However, using Aluminum for conductivity and Steel Wire for strength – ACSR ( Aluminum Clad Steel Wire Reinforced ) Wires are used.
Corrosion Resistance: Steel Wires rust easily. However, they can be coated with zinc, and such galvanized wires are corrosion resistant.
Steel Wires are predominantly used in mesh, fencing, ACSR strands, etc. These wires are galvanized using zinc to make them rust-proof. It takes more than 60-70 years for Hot dipped GI Wire to lose its zinc coating and start corroding.Though all wires are different, their manufacturing process is quite similar. This article will explain in detail how GI Wire is made
India is one of the largest manufacturers of Steel Wire. It ranks 2nd in the world in terms of production. The first position is held by China, while Japan is the third-largest manufacturer of Steel Wire.
Steel rods act as the core raw material for manufacturing Steel Wire. As these steel rods have scales formed over them after coming in contact with air, they need to undergo the Descaling process before using the GI wire manufacturing process.
The descaling process is nothing but the removal of oxide formation over the steel rods. Acids like Hydrochloric Acid etc., are used to remove the scale formed over these steel rods. The rods are then coated with Phosphate and Borax powder to remove the scale developed. This whole process is often referred to as the Pickling or Cleaning Process in the manufacturing of GI Wire.
The descaled wire rods are then wound around large bobbins. They are then made to pass through a series of Wire Drawing Machines. These steel rods pass through different dyes of various sizes to draw a wire of the required size.
The dyes used for drawing these steel rods to the desired size are made using hard materials like Tungsten. Please note a steel wire cannot be drawn to the desired size by just passing through a single dye of the desired size. It needs to pass through multiple blocks of dyes to reduce its size gradually. The Wire drawing process is essentially a process in which tension is progressively applied on steel rods to get the desired size steel wires.
The resulting output from the Wire drawing process is steel wire of the desired size. These wires are also often referred to as “Black Wires” as they are characteristically black.
The black steel wires thus manufactured using Wire Drawing Process undergo galvanization to produce Galvanized Iron Wire or GI Wire as it is commonly referred to. There are two main types of Galvanization process viz. Electroplating and Hot-Dipped Galvanization.
Steel wires coated with zinc by electroplated galvanization are known as electro galvanized wires. Here, a thin coating of zinc is bonded to the steel wires’ outer surface by electroplating.
The steel wires are immersed in a saline bath containing zinc at the anodes. As soon as steel wires are placed at the cathode, the zinc gets bonded to the steel wires firmly.
Hot-dipped galvanized wires are galvanized steel wires dipped in a molten zinc bath at a temperature of 460ºC after a thorough cleaning. Once it is removed from the molten tub, the coating of zinc settles on the steel wire giving it a resilient structure.
Yes, galvanized can be either a hot-dipped galvanized wire or electro galvanized wire. Hot dipped is a galvanized wire where the zinc metal is coated by dipping the wire in a molten zinc bath at a temperature of 460ºC and then cooled slowly.
With a history of more than 20 years in steel and in-depth knowledge of the wire industry, Systematic Group is one of India’s leading GI wire manufacturers. We are one of the reliable suppliers for Hot Dipped Galvanized Wires, High Carbon & Low Carbon Steel Wires, ACSR Wires providing the best quality wires at affordable prices to all our valuable clients.
We are one of the leading technology companies in steel wire transformation and coatings. Systematic Group is one of the top wires exporters in many parts Asia, African & European Countries.
The GI wires thus formed are sometimes made to pass through Stranding machines to produce strands of GI wire, also referred to as GI Steel Wire Strand.